Note: Descriptions are shown in the official language in which they were submitted.
Method of of Producing an Induction Component, and Induction
Component
The invention relates to a method of producing an induction
component and to an induction component produced by this
method.
A method of producing an induction component or inductor is
already known (KR 10-1044607). A coil core, a coil casing and
a cover made of a metallic magnetic powder are produced here
and pressed in a mould with the previously wound coil. The
winding ends are located in the region of the end side of the
inductor thus produced.
In the case of a further known method (KR 10 1044 608), a
multiplicity of connection terminals are incorporated in a
first mould and a multiplicity of individual coils are
incorporated in a second mould. The two moulds are positioned
one upon the other and the coil connections are welded to the
connection terminals.
In the case of yet a further known method (KR 10 2011
0100096), a coil core, coil casing and coil cover are pressed
in a mould together with the coil. Electrical contact is made
at the winding ends, which are located in the end surface of
the resulting inductor, by sputtering.
It is an object of the invention to provide a method of
producing induction components which gives rise to high-
quality induction components and is easy to carry out.
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The method thus provides for individual coils to be wound.
These coils may be of any desired shape. The wire used for
this purpose may likewise have any desired cross section. A
block made of an in particular pulverulent and/or
ferromagnetic substrate is produced, and the coils are
embedded therein with predefined orientation. It is ensured
here that the winding end which forms the start of the winding
has a certain orientation in relation to the block. A pre-
pressing operation then takes place in order to produce a
certain level of homogeneity within the block and to fix the
coils spatially within the block.
The pre-pressed block is positioned on a plate, which has a
marking for each coil. The marking is assigned in particular
to the start of the winding. The combination made up of block
and plate is pressed. The substrate of the block here is
compacted and, inter alia, an impression of the marking is
generated in that side of the block which is assigned to the
plate. The marking indicates to us the orientation of the coil
and, in particular, the position of the start of the winding
of the coils. It is preferably the case that the coils and the
associated markings are arranged at predetermined spacings.
The surface of the block may be subdivided into non-
overlapping regions, each region being assigned to precisely
one coil. The markings, then, are arranged such that they end
up located in each case within a region which is assigned to a
specific coil. The markings are advantageously arranged such
that, once the block has been divided up into induction
components, each induction component has an impression of a
marking on its upper side. The upper side of the induction
component is located opposite an underside of
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the induction component with the connection contacts
and/or winding ends exposed.
The pre-pressing operation can take place
isostatically, in order to compact the substrate of the
block in as homogenous and crack-free a manner as
possible.
Following the pressing operation, the block is released
from the bearing plate and the ends of the coil
windings are exposed. In the case of a cross-
sectionally round winding wire, it is also possible for
up to approximately half the cross section of the wire
to be removed.
The exposed ends of the coil windings are provided with
connection contacts.
The block is divided up to form the induction
components each containing at least one coil or a
double coil.
If desired in any individual case, it is also possible
for the block to be divided up into induction
components containing more than one coil.
In a development of the invention, provision can be
made for the block to be formed by virtue of
ferromagnetic powder being pressed in a pressure
procedure. For example, use can be made of an iron-
powder mixture having an iron fraction of for example
9896.
In a development of the invention, the winding ends of
the coil, at which electrical contact has to be made,
can be bent such that their end region runs
transversely to the axis of the coil.
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In particular, provision can be made for the winding
ends to project beyond the outer contour of the coil
body.
In yet a further development, provision can be made
according to the invention for use to be made, for
producing the coils, of insulated wire, in particular
enamel-insulated wire.
It is possible, and falls within the context of the
invention, for a coil to be provided with a core before
being embedded in the block. This core can also he used
for example as a holder for the wire during the winding
operation. In this case, the wire is thus wound up onto
the core.
It likewise falls within the context of the invention
for the coil to be wound without a core and to be
embedded in the block without a core. In this case, the
coil core can be formed by the introduction of the
substrate powder into the interior of the coil and the
subsequent pressing operation.
In order to carry out the pre-pressing operation,
provision can be made for the block or the substrate
with the coils inserted to be incorporated in a
moulding press and for a pre-pressing operation to be
carried out in this moulding press.
The pre-pressing operation can preferably take place in
accordance with a time/pressure profile. This profile
is selected here such that there is no damage to the
insulation of the wire of the coils or to the coils
themselves.
It was mentioned in the introduction that the block
with the coils incorporated therein is positioned on a
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bearing plate prior to the isostatic pressing operation
being carried out. That side of the block which is
located on the bearing plate later forms the upper side
of the induction component, which is thus located
opposite the underside, which is intended for being
applied to the printed circuit board. Using a bearing
plate having a low level of surface roughness ensures
that the upper side of the induction component is
likewise smooth. This improves the possibility of
picking and placing the induction components with the
aid of a suction gripper. For example, use is made of a
bearing plate with a surface roughness of R = 0.1 pm or
less, as a result of which it is possible to use very
small suction grippers.
In the development of the invention, prior to the
isostatic pressing operation being carried out, a
material layer made of an elastic material, for example
a silicone mat, is positioned on that side of the block
on which the winding ends of the coils are located.
This is intended to avoid, during the isostatic
pressing operation, disadvantageous deformation of the
underside of the resulting induction components,
particularly in the region of the winding ends and thus
of the subsequent wire outlet.
In a development of the invention, provision can be
made for the unit made up of bearing plate, pre-pressed
block and the layer of elastic material to be evacuated
in a gas-tight manner and to be introduced into a
liquid-filled pressure vessel, in which the isostatic
pressing operation is carried out under a certain
pressure and/or at a certain temperature. The pressure
and/or the temperature can follow a predetermined time
course.
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Following completion of the isostatic pressing
operation, the operation of exposing the winding ends
can take place mechanically, not just the insulation of
the winding ends being removed, but also the wire
possibly being provided with a greater contact-making
surface. For example, the operation of exposing the
winding ends can take place by milling, possibly a
round winding wire having up to half its cross section
milled away.
Electrical contact is then made at the exposed winding
ends using a known method.
The following operation of dividing up the block
containing the multiplicity of coils can be carried out
with the aid of known methods, for example by the block
being sawn up mechanically.
Further features, details and advantages of the
invention can be gathered from the claims and the
abstract, the wording of both is incorporated to the
contents of the description by reference, from the
following description of preferred embodiments of the
invention and with reference to the drawing, in which:
Figure 1 shows a perspective view of a coil;
Figure 2 shows the side view of the coil from Figure 1;
Figure 3 shows a section through the block, with coils
incorporated therein, during the pre-pressing
operation;
Figure 4 shows the isostatic pressing operation;
Figure 5 shows the method step of exposing the winding
ends of the coils;
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Figure 6 shows the result of the operation of exposing
the winding ends;
Figure 7 shows the induction components produced by the
block being divided up;
Figure 8 shows the perspective view of an induction
component according to the invention; and
Figure 9 shows the induction component from Figure 8 in
a partially open state.
The method proposed by the invention will now be
explained with reference to an example.
Figure 1 shows the perspective view of a coil 8, which
has the winding ends 6, 7 at its one axial end,
illustrated at the top in Figure 1. The two winding
ends 6, 7 are bent such that they run transversely to
the axis of the coil 8 and project outwards beyond the
outer contour of the coil 8. The two winding ends 6, 7
also run along a diameter of the coil. The coil 8 has
two layers of windings arranged one inside the other.
Figure 2 shows the coil 8 from Figure 1 from the side.
It can also be seen here that the winding ends 6, 7 of
the coil-forming winding project beyond the outer
contour of the coil and are located in a common plane.
Continuing the method, then, the plurality of coils 8
are embedded in a block made of a substrate, wherein
the substrate is formed in particular from a powder, in
particular an iron-powder mixture.
Figure 3, then, shows the arrangement of a block 1 in a
moulding press 9, wherein the block 1, prior to the
press being closed, can consist of a first substrate
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powder. For the operation of embedding the coils in the
block 1, it is ensured that the winding ends assume a
certain orientation in relation to the side edges of
the block 1. The winding ends 6, 7 are located in a
layer 10. The block 1 is located on a support plate 11
in the moulding press. The upper part 12 of the
moulding press 9 is pressure-activated in the direction
of the arrows 13, wherein the course taken by the
pressure corresponds to a time/pressure profile. This
profile is selected such that the energy absorbed
cannot result in damage to the wire insulation or to
the pre-pressed structure. It is possible, for example,
for a pressure of 250 kg/cm2 to be applied during this
pressing operation of the first substrate powder. If
appropriate, in order to maintain desired dimensions of
the block 1, it is possible, following the first
pressing operation, for a second substrate powder to be
applied to the block 1 and for a second pressing
operation to take place. If necessary, in order to
achieve desired dimensions of the block 1 or of the
induction components produced therefrom in the moulding
press 9, it is possible for the block 1 to be provided
with a further layer made of substrate powder, this
layer then being pressed. The substrate powder here may
be the same as, or different from, the first substrate
powder. Using different substrate powders, with
differently magnetic properties, for the individual
pressing operations makes it possible to set a desired
level of inductance for the induction components
produced. It is possible, for example, for a pressure
of 200 to 270 kg/cm2 to be applied during this second
pressing operation. Once the amount of time
corresponding to the profile has elapsed, the operation
of pre-pressing the block 1 with the coils 8 has thus
been completed.
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The block 1 is then removed from the moulding press 9
from Figure 3 and introduced into a pressure vessel 14,
which is illustrated schematically in Figure 4. The
pressure vessel 14 contains a bearing plate 15 with an
upper side which is directed towards the block 1 and of
which the surface quality does not exceed a roughness
of 0.1 pm, it therefore being possible for said bearing
plate also to be referred to as a polished plate. Said
upper side 16 contains, for each coil 8, a protrusion
17 which is in the form of a small cone and forms a
marking. Each of the cones 17 is associated with the
orientation of the winding ends 6, 7 of the respective
coil 8, in particular with the start of the winding. In
other words, the start of the winding of each coil 8 is
located opposite a respective cone 17. The block 1 is
positioned in an approximately oriented manner on the
bearing plate 15. A silicone layer 18 is then
positioned on the layer 10, which has been applied to
the upper side 2 of the block 1. The unit made up of
block 1, bearing plate 15 and silicone layer 18 is then
expediently packed in a liquid-tight manner and, if
appropriate, evacuated. Thereafter, the pressure vessel
14 is completely filled with liquid, for example with
water, and is subjected to pressure on all sides, as is
indicated by the arrows 19. The silicone layer 18
should prevent damage to the winding ends 6, 7, which
are contained in the layer 10, during pressure
activation. The pressure activation causes the cones 17
to generate a complementary depression 21 in the
underside 3 of the block 1. The pressure is
significantly higher, for example around at least ten
times the pressure, in particular 4500 kg/cm', during
the isostatic pressing operation than during the
preceding pressing operations. The isostatic pressing
operation can advantageously follow a temperature and
pressure profile over a time.
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During the pressure-activation operation, temperature
activation can also take place. The pressure activation
advantageously takes place in accordance with a
predetermined time/pressure profile. The temperature
activation can likewise follow a predetermined
time/temperature profile.
Following completion of the isostatic pressing
operation, the resulting block provided with the layer
is removed from the pressure vessel 14. The coils 8
10 are fully embedded in the block 1. The underside 3 of
the block 1 has formed in it the depressions 21 which
are produced by the cones 17; each constitute a marking
and are located opposite the respective start of the
winding of the coils 8.
Next, the upper side of the layer 10, which can still
be seen at the left-hand end of Figure 5, is removed
with the aid of a milling cutter 22 to the extent where
the winding ends 6, 7 of each coil 8 are freed of their
insulation and in particular up to approximately half
the cross section thereof is exposed. This is
illustrated in the right-hand part of Figure 5.
The result is a block 1, see Figure 6, in which the
winding ends 6, 7 of all the coils 8 have been exposed.
These winding ends 6, 7 can then be provided, by way of
a known method, with connection contacts.
Thereafter, the induction components, which are the
desired end products, are produced by virtue of the
block 1 being divided up, see Figure 7. Proceeding from
Figure 6, Figure 7 shows how individual inductors 24
are produced from the continuous block 1 by virtue of
the latter being sawn up.
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The following figure, Figure 8, shows a perspective
view of an inductor 24. The former underside 3 of the
block 1 now forms the upper side of the inductor 24.
This upper side can be seen to contain a hole 21, which
has been generated by the cone 17 of the support plate
15. Two connection-contact elements 25 are applied to
the former upper side of the block 1, said former upper
side forming the under side of the inductor 24, and are
connected electrically and mechanically to a respective
winding end 6, 7. This connection between the contact
elements 25 and the winding ends 6, 7 is indicated in
Figure 9, which does not illustrate the substrate,
which actually tightly encloses the coils 8. Since it
has been pressed by means of the polished bearing plate
15, the upper side of the inductor has a very low level
of surface roughness and can therefore be gripped
reliably for pick-and-place purposes by extremely small
suction grippers. Typically, the inductor 24 has an
edge length between approximately 1 mm and 5 mm. The
hole 21, which is designed in the form of a conical
blind hole, is an indication of the orientation of the
start of the winding, and therefore the induction
component 24 can be positioned automatically with
desired orientation of the start of the winding.
